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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Development of a High-Strength Low-Carbon Steel with Reasonable Ductility through Thermal Cycling

In this research work, cost-effective structural material synthesis routes have been adopted in the form of thermal cycling designed and applied on a low-cost material (AISI 1010 steel). The main synthesis route consists of two-step thermal cycling (designed with respect to iron–carbon phase diagram) combining short-duration holding in upper critical and intercritical temperature regimes and different cooling conditions (forced air cooling and ice-brine quenching). Accordingly, the adopted hierarchical design approach (from nanoscale onwards) with a combination of hard and soft phases (to attain an adequate balance between mutually exclusive strength and ductility properties) results in origin of a novel microstructure. The microstructure consists of dislocation-enriched martensite regions (possessing plate and lath morphologies in 1:4 ratio) containing nanosized cementite particles and α-ferrite regions containing submicroscopic cementite particles. As a consequence, an excellent combination of strength (UTS = 905 MPa) and ductility (%Elongation = 17) is achieved in the synthesized material.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Achieving ultra-high strength and ductility in equiatomic CrCoNi with partially recrystallized microstructures

Despite having otherwise outstanding mechanical properties, many single-phase medium and high entropy alloys are limited by modest yield strengths. Although grain refinement offers one opportunity for additional strengthening, it requires significant and undesirable compromises to ductility. This work therefore explores an alternative, simple processing route to achieve strength by cold-rolling and annealing an equiatomic CrCoNi alloy to produce heterogeneous, partially recrystallized microstructures. Tensile tests reveal that our approach dramatically increases the yield strength (to ~1100 MPa) while retaining good ductility (total elongation ~23%) in the single-phase CrCoNi alloy. Scanning and transmission electron microscopy indicate that the strengthening is due to the non-recrystallized grains retaining their deformation-induced twins and very high dislocation densities. Furthermore, load-unload-reload tests and grain-scale digital image correlation are also used to study the accumulation of plastic deformation in our highly heterogeneous microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Achieving high strength and ductility in traditionally brittle soft magnetic intermetallics via additive manufacturing

Intermetallic alloys possess exceptional soft magnetic properties, including high permeability, low coercivity, and high saturation induction, but exhibit poor mechanical properties that make them impractical to bulk process and use at ideal compositions. We used laser-based Additive Manufacturing to process traditionally brittle Fe–Co and Fe–Si alloys in bulk form without macroscopic defects and at near-ideal compositions for electromagnetic applications. The binary Fe–50Co, as a model material, demonstrated simultaneous high strength (600–700 MPa) and high ductility (35%) in tension, corresponding to a ~300% increase in strength and an order-of-magnitude improvement in ductility relative to conventionally processed material. Atomic-scale toughening and strengthening mechanisms, based on engineered multiscale microstructures, are proposed to explain the unusual combination of mechanical properties. Here, this work presents an instance in which metal Additive Manufacturing processes are enabling, rather than limiting, the development of higher-performance alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Deformation mechanisms and ductile fracture characteristics of a friction stir processed transformative high entropy alloy

Deformation mechanisms of a friction stir processed Fe 40 Mn 20 Co 20 Cr 15 Si 5 transformative high entropy alloy using three different process parameters were studied to explain the microstructural dependence of tensile response in these specimens. The relative strain hardening contribution due to transformation and twinning effects was different for the three different microstructural conditions and thus resulted in different magnitude of work hardening. Crystal plasticity simulations confirmed that synergistic activity of face centered cubic and hexagonal close packed slip and twin mechanisms resulted in sustained work hardening and enhanced uniform elongation. The non-uniform ductility and extent of void nucleation and growth in these specimens were limited. Nevertheless, fractography and X-ray microscopy of fractured tensile specimens verified that microstructural flexibility induced different propensities for void growth and ductile fracture mode. Thus, alloy design induced phase stability, adaptive phase evolution due to friction stir processing, extent and kinetics of martensitic transformation and related work hardening capability of the individual phases combined together to determine the overall tensile response. The crystallographic orientation dependence of deformation induced phase transformation was also thoroughly studied. Finally, this study included quantitative determination of the crystallographic orientation where resolved shear stress on leading and trailing partial dislocations favored separation of the partials to cause transformation at a critical value of applied stress.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Ultra-grain refinement creates FCC pure cobalt with high strength and high ductility

Although pure cobalt is generally known to have a hexagonal close-packed (HCP) structure at room temperature, we show that its high-temperature face-centered cubic (FCC) phase can be strongly stabilized through grain refinement, resulting in FCC pure cobalt at room temperature. Ultrafine-grained (UFG) FCC cobalt exhibits a hierarchical microstructure consisting of dense stacking fault (SF) networks in the dominant FCC grains and numerous SFs and thin FCC layers within a few HCP plates. This unique microstructure leads to a high tensile strength exceeding 1 GPa, together with a tensile elongation of over 35%, thereby surpassing the well-known strength–ductility trade-off of pure metals. In-situ synchrotron X-ray diffraction revealed that the UFG FCC cobalt exhibited a markedly enhanced deformation-induced FCC→HCP martensitic transformation, which provided sustained strain hardening through the transformation-induced plasticity (TRIP) effect. Furthermore, ultra-grain refinement dramatically suppressed premature void and crack formation, causing a transition in the fracture mode from brittle to ductile. These findings advance the fundamental understanding of the phase stability and TRIP-assisted deformation in elemental cobalt and offer new guidelines for the microstructure-driven design of high-performance cobalt-based structural alloys.

Metastability↗
DOE OSTI2023

Machine learning based approach to predict ductile damage model parameters for polycrystalline metals

Damage models for ductile materials typically need to be parameterized, often with the appropriate parameters changing for a given material depending on the loading conditions. This can make parameterizing these models computationally expensive, since an inverse problem must be solved for each loading condition. Using standard inverse modeling techniques typically requires hundreds or thousands of high-fidelity computer simulations to estimate the optimal parameters. Additionally, the time of a human expert is required to set up the inverse model. Machine learning has recently emerged as an alternative approach to inverse modeling in these settings, where the machine learning model is trained in an offline manner and new parameters can be quickly generated on the fly, after training is complete. Here, this work utilizes such a workflow to enable the rapid parameterization of a ductile damage model called TEPLA with a machine learning inverse model. The machine learning model can efficiently estimate the model parameters much faster, as compared to previously employed methods, such as Bayesian calibration. The results demonstrate good accuracy on a synthetic test dataset and is validated against experimental data.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Predicting ductility of Mg/SiCp nanocomposite under multiaxial loading conditions based on unit cell modeling

This article presents an investigation on the ductility of Mg/SiCp under nine different multiaxial loading conditions based on a unit cell (or called representative volumetric element, RVE) finite element model. The constitutive relationship of magnesium matrix is characterized by a model combined Lode angle dependent plasticity model with the CPB06 plasticity model, which is able to describe the tension-compression asymmetry in magnesium matrix. The debonding of the matrix-particle interface and matrix fracture are considered by the modified Mohr-Coulomb (MMC) fracture model. Simulation results show that the interface debonding and subsequent matrix fracture are responsible for the ductility and fracture of nanocomposite. The computational results with parametric studies are compared and well correlated with experimental data, and it finally gives a stress-based full fracture locus of Mg/SiCp nanocomposite.

42 ENGINEERING↗
DOE OSTI2020

Tailoring ductile-phase toughened tungsten hierarchical microstructures for plasma-facing materials

Biological materials, such as bones, nacre, etc., have been found to show attractive and unique combinations of stiffness, strength and fracture toughness. Research has been conducted in various engineering areas to mimic the naturally hierarchical microstructures or nanostructures of these materials to produce materials with optimum stiffness, high strength and fracture toughness for their intended structural applications. In the same objective, this work applies a multiscale microstructural approach recently developed to investigate the deformation and fracture behavior of ductile phase toughened tungsten (W) materials such as tungsten-nickel/iron (W-Ni/Fe) composites that possess lamellar-like and hierarchical “brick-and-mortar” (BAM) microstructures. First, the approach is used to simulate tensile loading of W-Ni/Fe specimens cut out from hot-rolled W-Ni/Fe plates which possess lamellar-like microstructures. The finite element model of the gage section of the specimen consists of a W-Ni/Fe dual-phase microstructural domain in which the constitutive behaviors of W and Ni/Fe phases are described by an elastic-plastic damage model. The predicted material stress-strain response and crack pattern development as a function of loading are then compared to the corresponding experimental results to determine the constitutive model parameters for W and Ni/Fe. Subsequently, the model parameters are used to analyze W-Ni/Fe BAM microstructures that are artificially created to investigate the effects of microstructural features and morphologies on the composite stress-strain response, damage, and fracture patterns. The modeling shows that regular BAM microstructures that experience bridging mechanism combined with crack penetration across W-phase regions exhibit significantly higher strengths than the rather random lamellar-like microstructures. More significantly, however adjusting the brick’s length-to-height ratio, the BAM microstructure can be designed to allow a more distributed damage zone which leads to increased strength, ductility and fracture energy.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Behavior of helium cavities in ion-irradiated W-Ni-Fe ductile-phase toughened tungsten

This study reports on the distribution of helium (He) cavities in a hot-rolled W-Ni-Fe ductile-phase toughened tungsten (DPT W) composite irradiated to a dose and a helium concentration that are comparable to those in the material after 5-year irradiation in a conceptual fusion power plant. Here, the DPT W sample consists of W particles embedded in a ductile-phase NiFeW matrix with a nominal composition of 90W-7Ni-3Fe by weight. It was hot-rolled to a thickness reduction by 87% (87R DPT W). Sequential irradiation of the material with 1.2 MeV Ni + ions to a fluence of 2.15×10 16 Ni + /cm 2 and 90 keV He + ions to 6.5×10 15 He + /cm 2 was performed at 973 K. Larger He cavities with a lower number density are observed in NiFeW than W. Helium cavities are aggregated preferentially along the NiFeW/W interphase boundary. This behavior is not observed along the W/W grain boundary under the same irradiation conditions. A similar distribution of He cavities with comparable sizes is observed in 87R DPT W irradiated with He + ions only, suggesting that the He cavity distribution is not significantly affected by pre-irradiation of Ni + ions at 973 K. The data from this study does not provide any evidence for formation of visible voids or Ni precipitates in W phase irradiated with Ni + ions only. Diffusion and clustering of He atoms and mobile vacancies during ion irradiation at 973 K are responsible for the formation and growth of the He cavities.

36 MATERIALS SCIENCE↗
DOE OSTI2017

A novel ultrafine-grained Fe−22Mn−0.6C TWIP steel with superior strength and ductility

A fully recrystallized ultrafine-grained (UFG) Fe−22wt.%Mn−0.6wt.%C twinning-induced plasticity (TWIP) steel with mean grain size of 576 nm was fabricated by cold rolling and annealing process. Tensile test showed that this UFG steel possessed high yield strength of 785 MPa, and unprecedented uniform elongation of 48%. The Hall-Petch relationship was verified from the coarse-grained (CG) regime to the ultrafine-grained (UFG) regime. The microstructures at specified tensile strains were characterized by electron backscattered diffraction (EBSD) and transmission electron microscopy (TEM). The microstructures and strain hardening behavior of the UFG TWIP steel were compared with the CG counterpart. The strong strain hardening capability of the UFG steel is supposed to be responsible for the high strength and good ductility. - Highlights: • A fully recrystallized Fe−22Mn−0.6C TWIP steel with mean grain size of 576 nm was fabricated. • The ultrafine-grained (UFG) steel exhibits strong strain-hardening capability, excellent strength and ductility. • The Hall-Petch relationship is fitted well from the CG regime to the UFG regime.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Fabrication and characterization of a novel β metastable Ti-Mo-Zr alloy with large ductility and improved yield strength

Highlights: • Ti-12Mo-5Zr alloy exhibits excellent combination of improved yielding strength (>650 MPa), high ductility (uniform elongation ≈30%) and work-hardening behaviour. • The superior performances arise from the synergic effects between phase transformation induced plasticity and twinning induced plasticity. • The ‘d-electron’ alloy design approach in Ti-12Mo-5Zr alloy, i.e. Zr substitution to Ti, validates the feasibility of yielding stress improvement of TWIP/TRIP titanium alloys. - Abstract: In this paper, a novel ternary β-metastable titanium alloy, Ti-12Mo-5Zr (wt%), was designed based on the “d-electron” alloy design theory. The Ti-12Mo-5Zr alloy displays excellent combination of improved yielding stress (>650 MPa), high ductility (uniform elongation ≈30%) and work-hardening behaviour. The detailed microstructural analysis indicates that the superior performances arise from the synergic effects between phase transformation induced plasticity (TRIP) and twinning induced plasticity (TWIP). Conforming to the design strategy, the improvement of mechanical performance results from the addition of Zr alloying element in substituting Ti, attributing to solution hardening effect and the increasing of critical resolved shear stress (CRSS) of stress induced martensitic transformation (SIM α″).

36 MATERIALS SCIENCE↗
DOE OSTI2016

Gradient twinned 304 stainless steels for high strength and high ductility

Gradient materials often have attractive mechanical properties that outperform uniform microstructure counterparts. It remains a difficult task to investigate and compare the performance of various gradient microstructures due to the difficulty of fabrication, the wide range of length scales involved, and their respective volume percentage variations. We have investigated four types of gradient microstructures in 304 stainless steels that utilize submicrotwins, nanotwins, nanocrystalline-, ultrafine- and coarse-grains as building blocks. Tensile tests reveal that the gradient microstructure consisting of submicrotwins and nanotwins has a persistent and stable work hardening rate and yields an impressive combination of high strength and high ductility, leading to a toughness that is nearly 50% higher than that of the coarse-grained counterpart. Ex- and in-situ transmission electron microscopy indicates that nanoscale and submicroscale twins help to suppress and limit martensitic phase transformation via the confinement of martensite within the twin lamellar. Twinning and detwinning remain active during tensile deformation and contribute to the work hardening behavior. We discuss the advantageous properties of using submicrotwins as the main load carrier and nanotwins as the strengthening layers over those coarse and nanocrystalline grains. Furthermore, our work uncovers a new gradient design strategy to help metals and alloys achieve high strength and high ductility.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Theoretical investigation on improving the ductility of Rh{sub 3}V by ternary addition

The band structure calculations are performed on the intermetallic compounds Rh{sub 3}V and Rh{sub 3}V{sub x}(Al){sub 1-x} by Full Potential Linearized Augmented Plane Wave(FP-LAPW) method. Total energies are calculated as a function of volume and fitted to Birch-Murnaughan equation of state to find the lattice parameter and the other ground state properties. The ductility of these compounds has been analyzed using Cauchy’s Pressure, Pugh Rule and Poisson’s ratio. From this study we observed that Rh{sub 3}V is brittle while its alloy Rh{sub 3}V{sub 0.875}Al{sub 0.125} is ductile. Electron density plots are illustrated and compared.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

Brittle-to-ductile transition of lithiated silicon electrodes: Crazing to stable nanopore growth

Using first principle calculations, we uncover the underlying mechanisms explaining the brittle-to-ductile transition of Li{sub x}Si electrodes in lithium ion batteries with increasing Li content. We show that plasticity initiates at x = ∼ 0.5 with the formation of a craze-like network of nanopores separated by Si–Si bonds, while subsequent failure is still brittle-like with the breaking of Si–Si bonds. Transition to ductile behavior occurs at x ⩾ 1 due to the increased density of highly stretchable Li–Li bonds, which delays nanopore formation and stabilizes nanopore growth. Collapse of the nanopores during unloading of the Li{sub x}Si alloys leads to significant strain recovery.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2016

Chaotic state to self-organized critical state transition of serrated flow dynamics during brittle-to-ductile transition in metallic glass

We study serrated flow dynamics during brittle-to-ductile transition induced by tuning the sample aspect ratio in a Zr-based metallic glass. The statistical analysis reveals that the serrated flow dynamics transforms from a chaotic state characterized by Gaussian-distribution serrations corresponding to stick-slip motion of randomly generated and uncorrelated single shear band and brittle behavior, into a self-organized critical state featured by intermittent scale-free distribution of shear avalanches corresponding to a collective motion of multiple shear bands and ductile behavior. The correlation found between serrated flow dynamics and plastic deformation might shed light on the plastic deformation dynamic and mechanism in metallic glasses.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

On the bulk compaction of brittle granular materials, Part III: Brittle‐to‐ductile transition and yield strength

A new and simple method is presented that enables the estimation of the yield strength (σ y ) of brittle materials (e.g., ceramics, glasses). It results from the combination of sufficiently high-stress compaction of their granular form, postmortem analysis of the crushed particles to identify the critical particle size corresponding to their brittle-to-ductile transition, and the use of a developed and simple analytical expression. Here, this method was an outcome from Part I of this three-paper series. To execute it, a granular brittle material is compacted to a sufficiently high stress, whereby the acting comminution produces both a fraction of particles having a sufficiently small size formed by ductile or plastic-like deformation and a remaining fraction of larger particles formed from brittle fracture. Postmortem microscopy is then used to identify the smallest particle size whose morphology indicates it formed from brittle fracture (d B2D ). The brittle material's σ y can then be estimated using a combination of the d B2D , Kendall's and Griffith's theories, a priori knowledge of the material's fracture toughness (K Ic ), and a fracture mechanics shape factor constant (Y) using σ y = √((32 π K Ic 2 )/(3 Y 2 d B2D )). The method's development and its use to estimate σ y for several vitreous silicates, α-quartzes, and NaCl are provided.

Compaction↗
DOE OSTI2013

Modeling the Ductile Brittle Fracture Transition in Reactor Pressure Vessel Steels using a Cohesive Zone Model based approach

Fracture properties of Reactor Pressure Vessel (RPV) steels show large variations with changes in temperature and irradiation levels. Brittle behavior is observed at lower temperatures and/or higher irradiation levels whereas ductile mode of failure is predominant at higher temperatures and/or lower irradiation levels. In addition to such temperature and radiation dependent fracture behavior, significant scatter in fracture toughness has also been observed. As a consequence of such variability in fracture behavior, accurate estimates of fracture properties of RPV steels are of utmost importance for safe and reliable operation of reactor pressure vessels. A cohesive zone based approach is being pursued in the present study where an attempt is made to obtain a unified law capturing both stable crack growth (ductile fracture) and unstable failure (cleavage fracture). The parameters of the constitutive model are dependent on both temperature and failure probability. The effect of irradiation has not been considered in the present study. The use of such a cohesive zone based approach would allow the modeling of explicit crack growth at both stable and unstable regimes of fracture. Also it would provide the possibility to incorporate more physical lower length scale models to predict DBT. Such a multi-scale approach would significantly improve the predictive capabilities of the model, which is still largely empirical.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Improving the Fracture Toughness and Ductility of Liquid-Phase Sintered WNiFe Tungsten Heavy Alloys by High-Temperature Annealing

Tungsten heavy alloys (WHAs) are candidates for use in fusion reactor divertors. Here, we characterize liquid-phase sintered WHAs with 90, 92.5, 95, and 97 (wt.%) tungsten (W), with a balance of a 0.7Ni–0.3Fe ductile phase. These WHAs show remarkable room temperature (RT) fracture toughness at the maximum load, K Jm , ranging from ≈ 38 to 107 MPa√m, compared to a monolithic W toughness of ≈ 8 MPa√m. In most cases, the fracture of WHAs occurs through stable crack tearing. However, the 97W WHA has the lowest toughness and fracture elastically in all but the smallest specimens. As lower Ni contents are desirable for fusion application, we explore the potential for improving the ductility and K Jm of WHAs using vacuum annealing at 1300 °C for 24 h. The microstructural observations reveal negligible changes in the WHA microstructure and constituent compositions. While annealing reduces the Vickers microhardness (HV), it does not significantly change the RT yield (σ y ) and ultimate (σ u ) strengths but results in beneficial increases in total elongation in the 95 and 97W WHAs by a factor of 2. RT tests on the precracked three-point-bend (3PB) bars show that annealing increases the K Jm of these WHAs, and in the case of the 97W WHA, the increase is from 42 to 92%, depending on the size of the specimen. Toughening is due to enhanced crack tip process zone microcracking and dilatation.

36 MATERIALS SCIENCE↗